Gehl R190 Skid Steer Troubleshooting

The Gehl R190 skid steer loader driveline system components: a 202.5 cu.in (3.3L) Yanmar 4TNV98C 4-cylinder naturally aspirated liquid-cooled diesel engine with a rated power of 69.3 hp (51.7 kW), and 1-speed or 2-speed transmission. The hydraulic system has a pump with a rated capacity of 18.5 gal/min (70.1 l/min). The system relief pressure is 3000 psi (207 bar). The Gehl R190 is equipped with a radial-lift loader boom, 80H roller chains, and 10x16.5 tires. The skid steer loader has a maximum lift height of 120.5" (3060 mm) to hinge pin and dump height of 91" (2310 mm). The rated operating capacity is 1900 lbs (862 kg), and tipping load is 3800 lbs (1724 kg).

Engine Troubleshooting

Engine hard to start or will not start

Air in the fuel lines - Bleed the fuel lines.
Fuel filter element is dirty - Service or replace the filter.
Dirty or damaged injection nozzles - Inspect nozzles and replace if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
Excessive valve clearance - Correct valve clearance needs to be set.
Defective fuel injection pump - Change or repair the pump.

Diesel starts and suddenly stops

Dirty air filter - Clean or replace element.
Fuel filter plugging - Service or replace the filter.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Damaged or clogged injectors - Clean fuel injectors or change it.
Fuel injection pump damage - Replacement or repair required.

Engine stops suddenly during operation

Low coolant temperature - Warm up the engine to required temperature.
Dirty fuel filter - Change filter element.
Air in the fuel system - Air bleeding.
Fuel injection nozzles fault - Check and replace nozzles if required.
Incorrect adjustment of fuel injection pump timing - Adjust according to specifications.

Engine stops at idle

Too low idle RPM - Adjust as required.
Fuel injection pump is faulty - Rebuild or replace pump.
Fuel injectors are faulty or clogged - Replace fuel injectors.
The valve clearance is not adjusted - Adjust to proper valve clearance.

Lack of engine power

Air filter is dirty - Replace or clean air filter element.
Clogged or burnt injection nozzle - Test injection nozzles and change if necessary.
Incorrect fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve out of adjustment - Check and adjust as required.
Wrong adjustment of low idle speed - Correct low idle adjustment.
Clogged fuel lines or hoses - Clean fuel system hoses and lines.
Cylinder head gasket is worn - Replace cylinder head gasket.
Worn or broken piston rings - Install new piston rings.

Engine overheats

Engine has a lack of coolant - Refill to the correct level and inspect system for leaks.
Engine oil level is insufficient - Fill the crankcase with engine oil.
Dirty radiator fins or defective radiator cap - Replace cap or clean radiator.
Loose or defective fan belt - The fan belt needs to be replaced.
Diesel engine overloaded - Load reducing is recommended.

Insufficient oil pressure

Not enough oil in the engine - Checking oil level and add if necessary.
Plugged engine oil filter - Service or replace engine oil filter.
Incorrect engine oil Drain and refill with oil of correct grade and viscosity.
Incorrect oil clearance in crankshaft bearing - Replace bearings.
Oil pump is damaged - Replace as required.

Abnormal engine noise or knocking

Lack of engine oil - Fill up the engine oil.
Low coolant temperature - Warm up the engine.
Fuel injection pump timing is not adjusted - Adjust as recommended.
Incorrect low idle setting - Normalize low idle speed.
Defective fuel injectors - Change or clean fuel injectors.
Connecting rod is defective or misaligned - Alignment procedure or replacement is required.
Scored or worn pistons - Pistons replacement required.

Drive System Troubleshooting

Machine is not moving forward or backward

Hydraulic oil level is low - Fill the system to proper hydraulic oil level.
Drive chain is damaged - Inspect drive chain and replace faulty parts.
Input drive shaft is worn - Rebuild or change.
Relief valve is damaged - Repair or change.
Plugged hydraulic filter or suction line - Check, clean, or change if necessary.
Foot or hand controls are damaged - Change or repair.
Worn drive motor or pump - Change or repair faulty component.

Power is too low

Clogged hydraulic oil filter - Change or service hydraulic filter.
Relief valve is defective or opened - Close or replace relief valve.
Transmission components are damaged or faulty - Inspect and change faulty parts.
Input drive shaft is defective - Repair or install a new drive shaft.
Air in hydraulic system - Air bleeding is required.

Drive system overheating

Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Plugged hydraulic fluid filter - Replace hydraulic filter.
Relief valve is worn or damaged - Service or change relief valve.
Drive pump or hydraulic motor malfunction - Inspect and change as required.
Oil cooler is clogged - Clean cooling fins as required.
Drive system overload - Reduce drive system load.

Drive system is excessively noisy

Improper oil viscosity - Use the specified type of oil.
Air leaks in hydraulic system - Air bleeding is required.
Defective drive pump or hydraulic motor - Change or repair faulty component.
Mechanical parts of drive system are damaged or worn - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system has overheating

Hydraulic pressure is incorrect - Correct adjustment is required.
Main relief valve malfunction or improper adjustment - Adjust the valve or replace if necessary.
Hydraulic oil is dirty - Change hydraulic oil.
Lack of hydraulic oil - Check oil level and add hydraulic oil as required.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Lift arm can't drop or lift

Lift controls are faulty - Replace or repair.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Hydraulic control valve failure - Install a new valve or repair it.
Broken hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Bucket tilt does not work

Bucket tilt controls are damaged - Replace or repair.
Hydraulic pump not working - Repair or install new hydraulic pump.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic bucket cylinder is broken - Repair or install a new cylinder.
Hydraulic oil is insufficient - Need to add oil.

Boom or bucket functions slowly

Defective hydraulic pump - Test the pump flow rate and install new pump if required.
Leaking hydraulic cylinder - Cylinder seals need to be replaced.
Insufficient hydraulic oil - Need to add oil.
Hydraulic control valve is faulty or out of adjustment - Repair or adjust properly.
Hydraulic system loosing pressure - Hydraulic pressure must be set correctly.

Bucket or boom is jerky

Hydraulic system is leaking air - Air bleeding is required.
Plugged hydraulic oil filter - Service or replace the hydraulic filter.
Hydraulic fluid contamination - The fluid must be changed.
Cylinder rod or tube is scuffed - Replace failed component.

Hydraulic pump makes excessive noise

Not enough oil or hydraulic system leaking - Remedy hydraulic leakage or refill oil as necessary.
Plugged hydraulic filter - Clean or replace the filter.
Clogged suction line - Suction line must be serviced.
Air trapped in hydraulic pump - Remove air from hydraulics.
Damaged pump parts - Replace or rebuild the pump.

Electrical Troubleshooting

Battery will not charge

Loose or corroded electrical wiring connections - Clean or tighten wiring connections.
Battery terminal clamps are faulty - Replace terminal clamps.
Dead cell in battery - Battery change required.
Worn or loose belt - Belt needs to be adjusted or replaced.

Starter cranks slowly

Battery capacity is low - Battery is drained, recharge it.
Battery will not hold charge - Battery needs service or replacement.
Disconnected wiring or bad battery terminals - Check wire connections and change or service terminals.

Starter doesn't crank

Battery is drained or defective - Need to charge or replace the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery power is low - Battery is drained, recharge it.
Starter motor is damaged - Change or repair starter.